HYDRAULIC PUMP

DRIVE ASSEMBLY

S2.00-3.00XL (S40-60XL [GM engine only])

[A187, B187, C187];

H2.00-3.00XL (H40-60XL [GM engine only]) [B177, C177];

H3.50-5.00XL (H70-110XL) [F005, G005];

S3.50-5.50XL (S70-120XL) [D004];

S3.50-5.50XM (S70-120XM) [E004, F004];

S6.00-7.00XL (S135-155XL, S135-155XL

S155XLS) [B024, C024]

PART NO. 897121

1900 SRM 339

SAFETY PRECAUTIONS

MAINTENANCE AND REPAIR

• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly

fastened, and that the load being lifted is balanced. Make sure the crane, cables, and
chains have the capacity to support the weight of the load.

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair

on electric lift trucks.

• Disconnect the battery ground cable on internal combustion lift trucks.

• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT

THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Mainte-
nance section.

• Keep the unit clean and the working area clean and orderly.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Always use HYSTER APPROVED parts when making repairs. Replacement parts

must meet or exceed the specifications of the original equipment manufacturer.

• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before

using force to remove parts.

• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs,

or if the unit needs repairs.

• Be sure to follow the WARNING and CAUTION notes in the instructions.

• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel

are flammable. Be sure to follow the necessary safety precautions when handling these
fuels and when working on these fuel systems.

• Batteries generate flammable gas when they are being charged. Keep fire and sparks

away from the area. Make sure the area is well ventilated.

NOTE:

The following symbols and words indicate safety information in this

manual:

WARNING

Indicates a condition that can cause immediate death or injury!

CAUTION

Indicates a condition that can cause property damage!

Hydraulic Pump Drive Assembly

Table of Contents

TABLE OF CONTENTS

General ...............................................................................................................................................................

Description .........................................................................................................................................................

Hydraulic Pump Drive Assembly Repair..........................................................................................................

Remove and Disassemble ..............................................................................................................................

Clean ..............................................................................................................................................................

Inspect ............................................................................................................................................................

Assemble and Install .....................................................................................................................................

Troubleshooting..................................................................................................................................................

This section is for the following models:

S2.00-3.00XL (S40-60XL [GM engine only]) [A187, B187, C187];

H2.00-3.00XL (H40-60XL [GM engine only]) [B177, C177];

H3.50-5.00XL (H70-110XL) [F005, G005];

S3.50-5.50XL (S70-120XL) [D004];

S3.50-5.50XM (S70-120XM) [E004, F004];

S6.00-7.00XL (S135-155XL, S135-155XL

, S155XLS) [B024, C024]

"THE

QUALITY

KEEPERS"

HYSTER

APPROVED

PARTS

1900 SRM 339

Description

General

This section has the description and repair procedures for the chain drive assembly for the hydraulic pump(s).

Description

The chain drive assembly transfers the power
from the engine to the hydraulic pump for the hy-
draulic system.

See Figure 1.

On H3.50-5.00XL

(H70-110XL) units, the chain drive assembly also
operates the hydraulic pump for the oil clutch sys-
tem.

The assembly has a drive sprocket, a leaf

chain and a driven sprocket.

The drive sprocket

fastens directly to the engine crankshaft. The driven

sprocket rotates on ball bearings. One bearing for
the driven gear is installed in the flywheel housing.
The other bearing for the driven gear is installed in
the housing for the torque converter or the oil clutch.
The leaf chain connects the two sprockets. Splines
in the driven sprocket engage with the splines on the
shafts of the pumps. Special blocks in the flywheel
housing prevent oscillations of the chain.

FLYWHEEL HOUSING

OIL SEAL

SHIMS

DRIVE SPROCKET

LEAF CHAIN

SPECIAL BLOCK (TOP)

SPECIAL BLOCK (BOTTOM)

BEARING

SNAP RING (DIESEL ONLY)

10. DRIVEN SPROCKET
11. HYDRAULIC PUMP

Figure 1. Chain Drive Assembly

Description

1900 SRM 339

On H3.50-5.00XL (H70-110XL), S3.50-5.50XL (S70-
120XL), and S3.50-5.50XM (S70-120XM) units, oil
from the powershift transmission circuit or the oil
clutch system circuit lubricates the sprockets, bear-
ings, and chain.

On S3.50-5.50XM (S70-120XM) units,

oil from

the powershift transmission circuit lubricates the
sprockets, bearings, and chain.

On S/H2.00-3.00XL (S/H40-60XL) units with the GM
engine, oil from the hydraulic system lubricates the

sprockets, bearings, and chain. See Figure 2. The oil
supply for the lubrication circuit comes from the re-
turn circuit of the steering system. From the steering
control unit, the oil flows to fittings at the torque con-
verter housing. One fitting supplies oil for lubrica-
tion. The other fitting supplies the oil to operate the
jet pump at the bottom of the torque converter hous-
ing. The jet pump removes the oil from the torque
converter housing and sends it back to the hydraulic
tank. A hose at the top of the torque converter hous-
ing is used as a breather for the housing.

RETURN OIL FROM
STEERING CONTROL UNIT

OIL LINE FOR LUBRICATION

TORQUE CONVERTER
HOUSING

FITTING

JET PUMP NOZZLE

JET PUMP

SPRING

O-RING

RETURN TO HYDRAULIC
TANK

10. BREATHER
11. JET PUMP FITTING

Figure 2. Lubrication Circuit S2.00-3.00XL (S40-60XL)

1900 SRM 339

Hydraulic Pump Drive Assembly Repair

REMOVE AND DISASSEMBLE

NOTE:

The hydraulic pump(s) can be removed

without removing or disassembling the pump drive
assembly. The powershift transmission or oil clutch
housing must be removed for disassembly of the
pump drive assembly. See the service manual sec-
tions that apply to the Powershift Transmission
- Repairs or Oil Clutch System for these units.
The repair information for the hydraulic pumps is in
the sections for the Hydraulic Pump, Hydraulic
System, and the Oil Clutch System.

Remove the hydraulic pump as follows (see Fig-
ure 1):

a. Put the lift truck on blocks. The hydraulic

pump must be removed from the bottom of
the lift truck.

b. Remove the battery and battery tray.

Remove the breather from the hydraulic tank
and put a plug in the tank fitting. Disconnect
the return line at the tank and put a cap on
the fitting.

d. Remove the hose between the hydraulic

pump and the tank. Put a cap on the fitting
at the tank.

Disconnect the lines to the steering control
unit and the main control valve. Put caps on
the lines.

Remove the capscrews for the pump and re-
move the pump from the flywheel housing.

Remove the oil line for the bearings at the fly-
wheel housing.

Remove two of the capscrews for the flywheel.
Install alignment pins in these holes to keep
the flywheel from falling. (Use capscrews with
the heads removed.)

Remove the remaining

capscrews for the flywheel. Do not remove the
drive sprocket.

Check that the leaf chain has not become too
long. See Figure 3. The chain must be replaced
if dimension X is more than 31.8 mm (1.25 in.).

STRAIGHT EDGE

LEAF CHAIN

DRIVE SPROCKET

DIMENSION X (CHAIN PUSHED DOWN)

DRIVEN SPROCKET

Figure 3. Chain Length

Remove the drive sprocket. Do not let the shims
fall. Remove the shim set and keep the shims
together. Remove the oil seal.

Remove the driven sprocket assembly and the
leaf chain. If the bearings need replacing, use a
puller to remove the bearings from the sprocket.

If the special blocks need replacing, remove the
two capscrews that hold each block to the hous-
ing.

If necessary, disassemble the jet pump assem-
bly [see Figure 2] on the S/H2.00-3.00XL (S/H40-
60XL) units as follows:

a. Remove the jet pump fitting from the torque

converter housing.

b. Remove the spring and the jet pump.

Remove the jet pump nozzle.

d. Remove the oil line from the torque converter

housing.

Hydraulic Pump Drive Assembly Repair

1900 SRM 339

CLEAN

WARNING

Cleaning solvents can be flammable and toxic
and can cause skin irritation.

When using

cleaning solvents, always follow the recom-
mendations of the manufacturer.

Clean all parts using solvent. Do not use steam or
gasoline to clean parts.

INSPECT

Inspect the sprockets and bearings for wear or dam-
age.

ASSEMBLE AND INSTALL

If the flywheel housing was removed, install
it on the engine.

Install the capscrews with

the O-rings. Tighten the capscrews to 50 N•m
(45 lbf ft). Install the seal in the flywheel hous-
ing. Use a sealant on the outside diameter of
the seal. Install the seal so that it is even with
the inside edge (flywheel side) of the flywheel
housing. See Figure 1, Figure 2, Figure 3, and
Figure 4.

If new bearings are needed, install them on the
driven sprocket. Install the special blocks in the
flywheel housing. Tighten the capscrews for the
blocks to 20 N•m (15 lbf ft).

Install the drive sprocket on the crankshaft with-
out the flywheel. Use shims between the crank-
shaft and the drive sprocket so that the distance
from the housing to the face of the sprocket is A
as shown in Figure 4.

Install the driven sprocket and the chain. On
diesel units, make sure the snap ring is on the

bearing that fits in the torque converter or oil
clutch housing. Install the flywheel on the drive
sprocket. Use a gasket sealant on the threads
and install the capscrews for the flywheel. On
GM engines, tighten the capscrews to 80 N•m
(60 lbf ft). On Perkins engines, tighten the cap-
screws to 120 N•m (90 lbf ft). Lubricate the chain
and sprockets with hydraulic oil.

Connect the oil line for lubricating the chain
drive assembly. Install the hydraulic pump. Use
a sealant (Hyster Part No. 264159) on the flange
of the pump. Connect the oil lines to the pump.

Install the powershift transmission as described
in the section Powershift Transmission -
Repairs. Install the oil clutch assembly as de-
scribed in the section for the Oil Clutch.

If removed, install the jet pump assembly (see
Figure 2) for the S/H2.00-3.00XL (S/H40-60XL)
units as follows:

a. Clean the bottom of the torque converter

housing and the jet pump nozzle. Use an
adhesive sealant (Hyster Part No. 264159)
and install the jet pump nozzle in the torque
converter housing.

b. Install the jet pump, spring, and O-ring in

the torque converter housing. Make sure the
jet pump fits over the jet pump nozzle. In-
stall the fitting that holds the jet pump in the
torque converter housing.

Install the oil line for lubrication to the fit-
tings on the torque converter housing.

1900 SRM 339

Troubleshooting

Figure 4. Chain Drive Assembly Parts

Legend for Figure 4

NOTE: NOT ALL UNITS SHOWN. OTHERS SIMILAR.

Model

Dimension A

S/H2.00-3.00XL

(S/H40-60XL)

28.5 ±01 mm

(1.12 ±0.004 in.) GM

H3.50-5.00XL

(H70-110XL)

S3.50-5.50XL

(S70-120XL)

33.7 ±0.1 mm

(1.33 ±0.004 in.)

Gas & LPG

S3.50-5.50XM

(S70-120XM)

33.7 ±0.1 mm

(1.33 ±0.004 in.)

Gas & LPG

S6.00-7.00XL (S135-

155XL, S135-155XL

S155XLS) (B024, C024)

29.7 ±0.1 mm

(1.17 ±0.004 in.) DSL

CRANKSHAFT

SHIMS

FLYWHEEL

DRIVE GEAR

DRIVEN GEAR ARRANGEMENT (WITH OIL
CLUTCH)

DRIVEN GEAR ARRANGEMENT (WITH
POWERSHIFT TRANSMISSION)

Troubleshooting

Most problems that can occur in the chain drive as-
sembly will cause noise that is not normal. Examples
of these problems are as follows: (1) bearing wear, (2)
sprocket wear, or (3) leaf chain wear. The leaf chain
can also break. If the leaf chain breaks, there will be
no pump output. To repair any of these problems, the
drive assembly must be disassembled.

One of the hydraulic pumps can also be causing noise.
With the unit running, actuate the system to put a
load on the pump. If the noise is gone, the hydraulic
pump is probably the cause of the noise and not the
pump drive assembly.

NOTES

____________________________________________________________

TECHNICAL PUBLICATIONS

1900 SRM 339

10/03 (8/02)(11/01)(10/97)(10/89)(3/89)(3/88)(8/86) Printed in United Kingdom

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